Photovoltaic module mounting assembly having a pin constraint

ABSTRACT

A mounting assembly for a photovoltaic (PV) module, and systems including such mounting assemblies, are described. In an example, the mounting assembly includes a top support and a bottom support having respective mounting walls, and holes through the mounting walls. A pin assembly may extend through the holes in the mounting walls to constrain the supports, for example, relative to a torque member of a solar-tracking PV system. The pin assembly may include end collars to engage and distribute loading from the torque member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/254,988, filed on Sep. 1, 2016, the entire contents of which arehereby incorporated by reference herein.

BACKGROUND

Some sun-tracking solar power systems, such as utility-scalephotovoltaic installations, are designed to pivot a large number ofsolar modules to track the movement of the sun. For example,sun-tracking solar power systems may include rows of solar modulessupported on torque tubes. The solar modules are commonly attached tosupportive structures using conventional fasteners, such as bolts orrivets. The supportive structures, in turn, are commonly attached to thetorque tubes by welded joints.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a solar-tracking photovoltaic(PV) system, in accordance with an embodiment of the present disclosure.

FIG. 2 illustrates a perspective view of a PV module assembly, inaccordance with an embodiment of the present disclosure.

FIG. 3 illustrates a side view of a PV module assembly, in accordancewith an embodiment of the present disclosure.

FIG. 4 illustrates a perspective view of a mounting assembly coupled toa torque member, in accordance with an embodiment of the presentdisclosure.

FIG. 5 illustrates a side view of a mounting assembly coupled to atorque member, in accordance with an embodiment of the presentdisclosure.

FIG. 6 illustrates a perspective view of a mounting assembly, inaccordance with an embodiment of the present disclosure.

FIG. 7 illustrates a side view of a mounting assembly including aretainer constraining a PV module, in accordance with an embodiment ofthe present disclosure.

FIG. 8 illustrates a perspective view of a mounting assembly including aretainer constraining a PV module, in accordance with an embodiment ofthe present disclosure.

FIG. 9 illustrates a perspective view of a retainer, in accordance withan embodiment of the present disclosure.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description.

This specification includes references to “one embodiment” or “anembodiment.” The appearances of the phrases “in one embodiment” or “inan embodiment” do not necessarily refer to the same embodiment.Particular features, structures, or characteristics may be combined inany suitable manner consistent with this disclosure.

Terminology. The following paragraphs provide definitions and/or contextfor terms found in this disclosure (including the appended claims):

“Comprising.” This term is open-ended. As used in the appended claims,this term does not foreclose additional structure or steps.

“Configured To.” Various units or components may be described or claimedas “configured to” perform a task or tasks. In such contexts,“configured to” is used to connote structure by indicating that theunits/components include structure that performs those task or tasksduring operation. As such, the unit/component can be said to beconfigured to perform the task even when the specified unit/component isnot currently operational (e.g., is not on/active). Reciting that aunit/circuit/component is “configured to” perform one or more tasks isexpressly intended not to invoke 35 U.S.C. § 112, sixth paragraph, forthat unit/component.

“First,” “Second,” etc. As used herein, these terms are used as labelsfor nouns that they precede, and do not imply any type of ordering(e.g., spatial, temporal, logical, etc.). For example, reference to a“first” end does not necessarily imply that this end is the first end ina sequence; instead the term “first” is used to differentiate this endfrom another end (e.g., a “second” end).

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature, and not necessarily mechanically.

In addition, certain terminology may also be used in the followingdescription for the purpose of reference only, and thus are not intendedto be limiting. For example, terms such as “upper,” “lower,” “above,”“below,” “in front of,” and “behind” refer to directions in the drawingsto which reference is made. Terms such as “front,” “back,” “rear,”“side,” “outboard,” “inboard,” “leftward,” and “rightward” describe theorientation and/or location of portions of a component, or describe therelative orientation and/or location between components, within aconsistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent(s) under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport.

“Inhibit”—As used herein, inhibit is used to describe a reducing orminimizing effect. When a component or feature is described asinhibiting an action, motion, or condition it may completely prevent theresult or outcome or future state completely. Additionally, “inhibit”can also refer to a reduction or lessening of the outcome, performance,and/or effect which might otherwise occur. Accordingly, when acomponent, element, or feature is referred to as inhibiting a result orstate, it need not completely prevent or eliminate the result or state.

Although many of the examples described herein are for solar-trackingphotovoltaic (PV) systems, the techniques and structures may applyequally to other non-solar-tracking or stationary solar energycollection systems, as well as concentrated thermal solar systems, etc.Moreover, although much of the disclosure is described in terms ofground-mounted solar-tracking solar energy collection installations, thedisclosed techniques and structures apply equally to other solar energycollection installations, e.g., rooftop solar installations.

The use of conventional fasteners, such as nuts, bolts, or rivets, toattach a PV module to a supportive structure, or to attach thesupportive structure to a torque tube, is commonplace today. Suchfasteners and welded joints represent a significant cost, both in termsof manufacturing material costs and installation costs. Reducing theconstruction cost of PV systems can significantly impact the feasibilityof constructing such systems as renewable energy sources contributing tothe power grid. Furthermore, construction costs can be reduced byassembling system components using fastening mechanisms other thanrivets or welds.

In an aspect, a mounting assembly for a PV module includes a top supportand a bottom support having respective mounting walls, and holes throughthe mounting walls. A pin assembly may extend through the holes in themounting walls to constrain the supports relative to a torque member ofa solar-tracking PV system. The pin assembly may include end collars toengage and distribute loading from the torque member. Accordingly, astructural truss system may be attached to a torque tube using alow-cost alternative to a welded joint.

In an aspect, a mounting assembly for a PV module includes a top strutto support the PV module, and a retainer fixed relative to the topstrut. The retainer may have an upright and retaining tab portionforming a receiving gap to receive the PV module. The retainer mayconstrain movement of the PV module mounted on the top strut. Forexample, the upright and retaining tab may prevent vertical or lateralmotion of the PV module mounted on the mounting assembly. Accordingly, aPV module may be attached to a mounting assembly using a low-costalternative to conventional fasteners, such as rivets.

The aspects described above may be realized by the mounting assembliesdisclosed herein. In the following description, numerous specificdetails are set forth, such as specific material regimes and componentstructures, in order to provide a thorough understanding of embodimentsof the present disclosure. It will be apparent to one skilled in the artthat embodiments of the present disclosure may be practiced withoutthese specific details. In other instances, well-known fabricationtechniques or component structures, such as specific types of actuatorsor techniques for coupling such actuators with system components, arenot described in detail in order to not unnecessarily obscureembodiments of the present disclosure. Furthermore, it is to beunderstood that the various embodiments shown in the figures areillustrative representations and are not necessarily drawn to scale.

By way of summary, disclosed herein is a mounting assembly including atop support member, a bottom support member, and a pin assembly having apin extending through the top support member and the bottom supportmember, is described. One or more of the top support member or thebottom support member may include mounting walls having concave surfacesto conform to a mounting structure of a PV system, e.g., a torquemember. The pin assembly can be preloaded in tension to secure thesupport members against the torque member. In an embodiment, the pinassembly may include end collars having larger diameters than the pin,and the end collars may insert through the mounting walls and the wallsof the torque member. Accordingly, the end collars may distribute shearloading applied by the torque member during use. One or more topstrut(s) and bottom struts be assembled to respective support members toform a rigid truss system. Accordingly, a PV module may be mounted onthe truss system above the torque member. As such, a PV laminate of PVmodule may rotate to track the sun when the torque member pivots about alongitudinal axis.

Referring to FIG. 1, a perspective view of a solar-tracking photovoltaic(PV) system is shown in accordance with an embodiment of the presentdisclosure. An electricity farm may include one or more solar-trackingPV systems 100. Solar-tracking PV system 100 may be considered amulti-drive system because several motor drives may be coupled to a sametorque member 102 to input torque to the torque member at longitudinallyseparated locations. In an embodiment, solar-tracking PV system 100includes several driven support assemblies 104 supporting torque member102. above the ground at the longitudinally separated locations. Eachdriven support assembly 104 may include a drive having a motor, e.g., astepper motor, and a gearset, e.g. a worm drive, to input torque totorque member 102 such that torque member 102 pivots about longitudinalaxis 106.

Solar-tracking PV system 100 may also include several non-driven supportassemblies 108 supporting torque member 102 above the ground. Forexample, a non-driven support assembly 108 may be positionedlongitudinally between a pair of driven support assemblies 104. Eachnon-driven support assembly 108 may support, and allow for rotation of,torque member 102 about longitudinal axis 106 without inputting torqueto torque member 102. Thus, non-driven support assemblies 108 mayfacilitate a stable rotation of torque member 102 without actuallydriving such rotation.

The support assemblies may support torque member 102 along longitudinalaxis 106. Driven support assemblies 104 may affect rotation of torquemember 102 about longitudinal axis 106 based on electrical inputsprovided or controlled. by a controller (not shown). The controller mayinclude a microprocessor or computer configured to control the deliveryof electrical power to motors of driven support assemblies 104 alongtorque member 102. For example, the controller may directly orindirectly, e.g., through control of a power supply, deliver anelectrical power input to a first driven support assembly 104 and anelectrical power input to a second driven support assembly 104.Accordingly, the motors and/or mechanical transmission components of thedriven support assemblies 104 may be simultaneously controlled bycontroller to input torque to the torque member 102. Thus, torque member102 may pivot or rotate about longitudinal axis 106.

Several PV modules 110 may be mounted on torque member 102 alonglongitudinal axis 106. For example, solar-tracking PV system 100 mayinclude a row of tens of PV modules arranged in a series. The series mayinclude, for example, 70-100 PV modules 110 between a first outward endand a second outward end of torque member 102. Thus, the row of PVmodules 110 may track a solar source, e.g., the sun or a reflectivesurface redirecting sunrays toward PV modules 110, when torque member102 pivots about longitudinal axis 106.

Referring to FIG. 2, a perspective view of a PV module assembly is shownin accordance with an embodiment of the present disclosure. A PV moduleassembly 200 may include PV module 110 mounted on a mounting assembly202. Mounting assembly 202 may include structural members to attach totorque member 102 (not shown) along longitudinal axis 106, and toprovide support to one or more PV modules 110. It will be appreciatedthat torque member 102 as described herein, i.e., a pivotable torquemember 102, is provided by way of example and is not intended to limitthe types of structures on which mounting assembly 202 may be mounted.For example, mounting assembly 202 may be mounted on a rail, beam, orany other general mounting structure that is fixed to a stationaryplatform, e.g., a rooftop or the ground. That is, rather than trackingthe sun, PV system 100 may be a fixed tilt PV system.

PV module assembly 200 may include several PV modules 110. For example,a first PV module 110 and a second PV module 204 may be mounted onopposite sides of a plane containing longitudinal axis 106. Each PVmodule 110 may include a PV laminate 206 mounted on a PV frame 208. PVlaminate 206 may include one or more solar collecting devices, e.g., PVcells, and PV laminate 206 and PV cells may be configured to receivesunlight for conversion into electrical energy. For example, the PVcells may be laminated between an optically transparent upper cover anda back cover. By way of example, the PV cells may be encapsulated by anencapsulant material between a glass top plate and a back sheet. Theback sheet may be optically transparent, e.g., formed from glass, oropaque. Thus, sunlight may transmit through one or more of the top plateor back sheet to the PV cells for conversion into electricity.

Each PV frame 208 may support a respective PV laminate 206 along anouter perimeter and/or a back surface of the laminate structure. Forexample, PV frame 208 may include one or more cross members supportingthe back surface of PV laminate 206. PV frame 208 may be mounted onmounting assembly 202, as described below. Accordingly, a front surfaceof PV laminate 206 may face a direction orthogonal to torque member 102to capture impinging sunlight as torque member 102 pivots aboutlongitudinal axis 106.

An orientation of PV module 110 may be considered a portrait orientationor a landscape orientation. The portrait orientation and the landscapeorientation may be defined based on a relationship of a long edge of PVmodule 110 relative to torque tube 102, or to a north-south direction.Torque tube 102 may ordinarily be oriented such that longitudinal axis106 extends in the north-south direction, allowing PV modules to rotatefrom east to west about longitudinal axis 106 to track the solar source.PV module 110 may have a rectangular profile, having a long edge and ashort edge. In an embodiment, a portrait orientation of PV module 110refers to an orientation of PV module 110 having the long edgeperpendicular to torque tube 102 and/or longitudinal axis 108 (FIGS.1-2). The landscape orientation, by contrast, may be an orientation ofPV module 110 having the short edge perpendicular to torque tube 102 andthe long edge parallel to torque tube 102. Accordingly, it will beappreciated that PV module 110 may be oriented in numerous mannersrelative to torque tube 102 within the scope of this description.

Referring to FIG. 3, a side view of a PV module assembly is shown inaccordance with an embodiment of the present disclosure. A pair of PVmodules may be butterflied about longitudinal axis 106. That is, firstPV module 110 may extend laterally outward from a vertical plane 302containing longitudinal axis 106, and second PV module 204 may extendlaterally outward in a second direction from vertical plane 302. Frontand rear surfaces of PV laminate 206 of each PV module may extend alongor be parallel to a lateral plane 304. Accordingly, each PV module mayextend in a lateral direction from an inward edge 306 to an outward edge308. Vertical plane 302 may extend along longitudinal axis 106orthogonal to the lateral direction, and thus, may define a first side310 and a second side 312 of mounting assembly 202 on either side oftorque member 102 (not shown).

In an embodiment, mounting assembly 202 includes a top support member314 and a bottom support member 316 aligned along vertical plane 302.Top support member 314 and bottom support member 316 may be mounted ontorque member 102 (not shown) and interconnected by a pin assembly 317.More particularly, torque member 102 may be disposed between top supportmember 314 and bottom support member 316 along vertical plane 302, andpin assembly 317 may extend through torque member 102 from top supportmember 314 to bottom support member 316. Thus, torque member 102 may begripped between top support member 314 and bottom support member 316 tosecure mounting assembly 202 to torque member 102 such that mountingassembly 202 pivots in coordination with torque member 102.

Mounting assembly 202 may include one or more struts to form a trusssystem. For example, one or more top struts 319 may extend orthogonal tovertical plane 302, and orthogonal to a pin axis 318 extending throughpin assembly 317. More particularly, a singular top strut 319 or a pairof top struts 319 may extend laterally outward from top support member314 to suspend, and support a weight of, PV module 110 above torquemember 102. Top strut(s) 319 may be separate truss system structuresattached to top support member 314, e.g., by a fastener joint.Alternatively, one or more top struts 319 may be integrally formed withtop support member 314. In the description below, top support member 314is described as a separate component. However, many of the same featuresmay be present in an embodiment having top support member 314 and topstrut(s) 319 formed as a unitary body.

The truss system provided by mounting assembly 202 may also include oneor more bottom strut 320. For example, several bottom struts 320 mayextend between bottom support member 316 and top strut 319. That is,each bottom strut 320 may be coupled to top strut 319 at a first end322, and may be coupled to bottom support member 316 at a second end324. Bottom struts 320 may be separate truss system structures attachedto bottom support member 316, e.g., by a fastener joint. Alternatively,one or more bottom struts 320 may be integrally formed with bottomsupport member 316. In the description below, bottom support member 316is described as a separate component. However, many of the same featuresmay be present in an embodiment having bottom support member 316 andbottom strut(s) 320 formed as a unitary body.

In an embodiment, bottom support member 316 may be formed by thecombination of separate portions of bottom struts 320. For example, oneskilled in the art could envision a pair of bottom struts 320 extendingfrom respective first ends 322 at top strut 319 to respective secondends 324 that overlap along pin axis 318. That is, bottom struts 320 mayinclude mounting surfaces, e.g., faces of respective tabs, that overlapeach other and include holes aligned along pin axis 318 to receive pinassembly 317. Accordingly, bottom struts 320 may stabilize the trusssystem to an underside of torque member 102, without requiring aseparate bottom support member 316 as described below.

Referring to FIG. 4, a perspective view of a mounting assembly coupledto a torque member is shown in accordance with an embodiment of thepresent disclosure. Torque member 102 may include a member wall 402extending around longitudinal axis 106. In an embodiment, member wall402 includes an annular cross-sectional area, and thus, torque member102 is a torque tube. A torque tube may include a cylindrical tubularmember (as shown) or any other tubular cross-sectional area geometry.For example, torque member 102 may include a rectangular cross-sectionalarea having a wall thickness 404. Accordingly, torque member 102 mayinclude an inner lumen, i.e., a space within an inner surface 406 ofmember wall 402. Torque member 102 can, however, have a solidcross-sectional area. For example, torque member 102 may include a solidrod having a circular or rectangular outer profile.

In an embodiment, top support member 314 and bottom support member 316are mounted on opposite surfaces of member wall 402. For example, topsupport member 314 may be mounted on a top side of outer surface 408 ofmember wall 402 along pin axis 318 and bottom support member 316 may bemounted on a bottom side of outer surface 408 of member wall 402 alongpin axis 318. Accordingly, top support member 314 may be mounted onmember wall 402, above a mounting hole 410 (FIG. 6) in the top surfaceof member wall 402, and bottom support member 316 may be mounted onmember wall 402., below a mounting hole 410 in the bottom surface ofmember wall 402. Mounting holes 410 on top side and bottom side oftorque member 102 may provide a pair of diametrically opposed holes toreceive pin assembly 317.

Referring to FIG. 5, a side view of a mounting assembly coupled to atorque member is shown in accordance with an embodiment of the presentdisclosure. Pin assembly 317 includes a pin 502 extending along pin axis318. More particularly, pin 502 may extend through mounting holes 410 oneither side of member wall 402 and through the inner lumen of torquemember 102. Furthermore, pin 502 may extend through both top supportmember 314 and bottom support member 316.

In an embodiment, top support member 314 includes a top mounting wall504 mounted on torque member 102. Similarly, bottom support member 316may include a bottom mounting wall 506 mounted on torque tube member.Each mounting wall may be configured to be stably attached to memberwall 402. For example, when member wall 402 has an annularcross-sectional profile, one or more of top mounting wall 504 or bottommounting wall 506 may include a concave surface facing outer surface 408of member wall 402. That is, top mounting wall 504 may include a concavedownward surface 508 facing bottom mounting wall 506, and bottommounting wall 506 may include a concave upward surface 510 facing topmounting wall 504. The concave surfaces may conform to member wall 402.Thus, the respective mounting walls of top support member 314 and bottomsupport member 316 may stabilize mounting assembly 202 against torquemember 102.

The curvature of top mounting wall 504 and bottom mounting wall 506 maynot be necessary to stabilize mounting assembly 202 against torquemember 102. For example, at least one of the mounting walls may have aflat surface facing torque member 102, e.g., the mounting walls may belaterally oriented planar walls. In such case, stability of mountingassembly 202 may come not from the conforming surfaces of the assembledstructure, but rather, may stem from the components being squeezedtogether by an external load.

The external load pressing top support member 314 and bottom supportmember 316 against torque member 102 may be a compressive force appliedby pin assembly 317 along pin axis 318. In an embodiment, top supportmember 314 includes a top support member hole 512 extending through topmounting wall 504 in alignment with pin axis 318. Similarly, bottomsupport member 316 may include a bottom support member hole 514extending through bottom mounting wall 506 in alignment with pin axis318. Thus, pin 502 of pin assembly 317 may extend along pin axis 318through top support member hole 512, bottom support member hole 514, andmounting holes 410 such that an upper end of pin 502 is above topmounting wall 504 and a lower end of pin 502 is below bottom mountingwall 506. Furthermore, pin 502 may include a head, nut, split pin,flange, or a similar feature at one or both end to constrain pin 502relative to top support member 314 and bottom support member 316. In anembodiment, pin 502 includes a bolt head at one end and a threaded endat another end that may be assembled to a nut 516 to generate an axialclamping load on the support members 314, 316. More particularly, nut516 may be tightened to squeeze top support member 314 and bottomsupport member 316 against torque tube. Thus, the support members may bestabilized against torque member 102.

It will be appreciated that, when pin 502 is fixed in space along pinaxis 318, rotation of top support member 314, bottom support member 316,and torque member 102 relative to each other about longitudinal axis 106is resisted by pin assembly 317. By extension, when torque member 102pivots about longitudinal axis 106, member wall 402 exerts a rotationalload on pin 502 that is transmitted to top support member 314 and bottomsupport member 316 to rotate mounting assembly 202 about longitudinalaxis 106 and to tilt PV module 110 toward the sun. The loading betweentorque member 102 and pin assembly 317 may generate shear stresses thatcan be designed for to avoid system failure.

In an embodiment, pin assembly 317 includes one or more end collars 518.For example, a respective end collar 518 may be mounted at the upper endof pin 502 and/or the lower end of pin 502. End collars 518 may beseparate structures, e.g., thick-walled tubular structures having holesto receive pin 502, or end collars 518 may be integral to pin 502. Thatis, pin 502 may be formed to include a middle section having a pindiameter 520 and one or more end sections having a larger hub diameter528.

The respective end collars 518 may be disposed in top support member 314and/or bottom support member 316. More particularly, a first end collar518 may be disposed in top support member hole 512 and a second endcollar 518 may be disposed in a bottom support member hole 514. Endcollars 518 may be configured to distribute a load applied by torquemember 102 to pin 502.

In an embodiment, distribution of shear stress may be achieved by endcollar 518 having collar diameter 528 greater than pin diameter 520. Forexample, collar diameter 528 of at least one end collar 518 of pinassembly 317 may be at least twice pin diameter 520. As such, endcollars 518 may be sized to accommodate shear loads applied by torqueduring use, e.g., by wind loading acting on torque member 102, and pin502 may be sized to accommodate tension loads applied during systeminstallation, e.g., by tightening nut 516 to hold the PV module assemblytogether. It will be appreciated that the stricture of pin assembly 317may realize cost advantages as compared to a pin 502 having a constantdiameter, which may be wider in a middle section than is required by thepin function.

A structure of end collar 518 may also include a collar flange portion.Collar flange 524 may act as a stop to limit an insertion depth of endcollar 518 into support member holes 512, 514 and mounting holes 410. Tothat end, collar flange 524 may include a flange diameter 526 greaterthan collar diameter 528. Thus, collar flange 524 may interfere withouter surfaces 408 of the mounting walls 504, 506 and/or member wall402. That is, collar flanges 524 may be located outside of the supportmembers 314, 316 and may press inward on the support members when nut516 is tightened to place pin 502 in tension.

Each end collar 518 may extend through top mounting wall 504 or bottommounting wall 506 from collar flange 524 outside of support members 314,316. That is, end collar 518 may have a collar height 530 between collarflange 524 and collar end 522. Collar height 530 may be sufficient toreduce the likelihood that collar end 522 will dislodge from supportmember holes 512, 514 or mounting holes 410 during use. Moreparticularly, end collar 518 may extend from collar flange 524 outsideof support members 314, 316 to collar end 518 between the supportmembers. For example, collar end 518 may be disposed within the innerlumen of torque member 102. Moreover, collar end 522 may extend into theinner lumen to a sufficient depth such that any jostling in theassembled system does not cause collar end 518 to retract above (orbelow) the outer surface 408 of member wall 402. In an embodiment, eachend collar 518 includes collar height 530 that is at least twice wallthickness 404 of member wall 402 and/or a thickness of a respectivemounting wall. For example, collar height 530 may be at least twice adistance between an outer surface 408 of top mounting wall 504 and theinner surface 406 of member wall 402.

Referring to FIG. 6, a perspective view of a mounting assembly is shownin accordance with an embodiment of the present disclosure. Top supportmember 314 and bottom support member 316 may be separate components fromstruts of mounting assembly 202, and thus, the support members may beconfigured to attach to the struts to form a rigid truss system. Forexample, the support members may include respective bracket walls 602extending from respective mounting walls. For example, one or morebracket wall 602 may extend vertically upward from top mounting wall504, and one or more bracket wall 602 may extend vertically downwardfrom bottom mounting wall 506. In an embodiment, each support member mayinclude a pair of bracket walls 602 spaced apart in the longitudinaldirection to provide a gap for receiving top strut(s) 319 and/or bottomstruts 320. Furthermore, each bracket wall 602 may include one or morebracket holes to receive a fastener such as a pin or a bolt, which mayextend through a strut received within the gap between bracket walls602. Accordingly, respective struts may be fastened to bracket walls 602of the support members, and thus, the struts may extend outward from thebracket walls 602 to connect to each other, e.g., at first end 322 ofbottom strut 320. For example, top strut 319 may extend outward from topmounting wall 504 to allow PV frame 208 to be mounted on top strut 319above torque member 102.

Outermost bracket holes 604 of bracket walls 602 may be separated by alateral distance. For example, bracket holes 604 of top support member314 may be symmetrically disposed about vertical plane 302 containingpin axis 318 and separated by a first lateral distance, and bracketholes 604 of bottom support member 316 may be symmetrically disposedabout vertical plane 302 and separated by a second lateral distance. Inan embodiment, the second lateral distance between bracket holes 604 ofbottom support member 316 is greater than the first lateral distancebetween bracket holes 604 of top support member 314. For example, thelocation(s) at top strut(s) 319 attach to top support member 314 may belocated above (within) a profile of torque member 102 when viewed fromabove, and the locations at which bottom struts 320 attached to bottomsupport member 316 may be laterally outside of (not within) the profileof torque member 102. Such a relative positioning of the respectivefastening points may improve tool access and ease system installation.

As shown in FIG. 6, end collars, rather than being collar components ofpin assembly, may be integrally formed with the support members. Forexample, top support member 314 may include a boss 606 extending fromconcave downward surface 508 of top mounting wall 504, and bottomsupport member 316 may include boss 606 extending from concave upwardsurface 510 of bottom mounting wall 506. Bosses 606 may have a geometrysimilar to the portion of end collar 518 extending from collar flange524, as described above. Accordingly, bosses 606 may distribute shearstress applied by torque member 102. As with pin assembly 317, pin 502may extend through bosses 606, and may be tensioned by nut 516 (notshown).

Referring to FIG. 7, a side view of a mounting assembly including aretainer constraining a PV module is shown in accordance with anembodiment of the present disclosure. Mounting assembly 202 may includefeatures to constrain relative movement of PV module 110 in one or moredirections when PV frame 208 is mounted on top strut 319. In anembodiment, a retainer 702 is fixed relative to top strut 319. Forexample, a base 704 of retainer 702 may be fastened to bracket wall 602of top support member 314. Alternatively, retainer 702 may be attachedto top strut 319, torque member 102, or any other component fixedrelative thereto. Furthermore, in an embodiment, retainer 702 may beintegrally formed with a component of mounting assembly 202, such as topsupport member 314.

A geometry of retainer 702 may include a vertical component and alateral component. Retainer 702 may include an upright 706 extendingorthogonal to the lateral direction, i.e., orthogonal to lateral plane304. Upright 706 may include a post, a vertical tab, or anothervertically oriented feature extending along vertical plane 302. A heightof upright 706 may be sufficient to dispose an upper end of upright 706laterally between inward edges 306 of adjacent PV frames 208. Forexample, upright 706 may separate PV frames 208, i.e., act as a spacerto prevent inward edge 306 of PV module 110 on first side 310 ofvertical plane 302 from being pressed against inward edge 306 of secondPV module 204 on second side 312 of vertical plane 302. Accordingly,upright 706 may constrain lateral movement of PV frames 208 to maintainPV frame 208 of PV module 110 on first side 310 of top strut(s) 319 andto maintain PV frame 208 of second PV module 204 on second side 312 oftop strut(s) 319.

Retainer 702 may include one or more retaining tab 708 extendinglaterally from upright 706 to a lateral end 710. A length of retainingtab 708, i.e., a distance between upright 706 and lateral end 710, maybe long enough that lateral end 710 terminates beyond inward edge 306 ofPV frame 208. More particularly, inward edge 306 may be between upright706 and lateral end 710 along the length of retaining tab 708. In anembodiment, retaining tab 708 extends from upright 706 above top strut319 to form a receiving gap 712 that extends between retaining tab 708and top strut 319. Accordingly, a portion of PV module 110 may bereceived within receiving gap 712, e.g., by sliding PV frame 208 overtop strut 319 toward upright 706.

Referring to FIG. 8, a perspective view of a mounting assembly includinga retainer constraining a PV module is shown in accordance with anembodiment of the present disclosure. Inward edge 306, which may be aninward facing surface of a structural member of PV frame 208, mayinclude a slot 802. Slot 802 may be formed in inward edge 306 within aperimeter of the surface facing upright 706. Thus, when PV frame 208 ismounted on top strut 319, a retained portion 804 of inward edge 306 maybe slid under retaining tab 708 into receiving gap 712, and retainingtab 708 may insert into slot 802 over retained portion 804, such thatretaining tab 708 extends through slot 802 and engages slot 802 as a keyin a hole. As such, retaining tab 708 may extend laterally over PVmodule 110 such that inward edge 306 of PV module 110 is withinreceiving gap 712.

When retainer 702 is positioned within slot 802 of inward edge 306, PVframe 208 may be constrained in several directions. For example, asdescribed above, PV frame 208 of PV module 110 may be unable to slidefurther toward second PV module 204. Similarly, retaining tab 708 mayconstrain longitudinal and vertical movement of PV frame 208 because anymovement in those directions may be limited by a size of slot 802.

Referring to FIG. 9, a perspective view of a retainer is shown inaccordance with an embodiment of the present disclosure. Retainer 702may include a hook portion 902 extending downward from lateral end 710toward base 704 and/or top strut 319. Hook portion 902 may define arecessed wall 904 of retaining tab 708. That is, recessed wall 904 maybe vertically higher than a point of hook portion 902, and may be nearerto upright 706 than the point. Accordingly, hook portion 902 may providea retention feature to hook around the wall forming inward edge 306 ofPV frame 208. For example, recessed wall 904 may have a recess width 906greater than a thickness of the wall forming inward edge 306 of PV frame208. As such, hook portion 902 may constrain lateral movement of PVframe 208 in the lateral direction away from upright 706.

Referring again to FIG. 3, lateral movement of PV module 110 relative tomounting assembly 202 may also be limited by a fastener 350. Fastener350 may join PV frame 208 to top strut 319 at a fastener joint.Furthermore, the fastener joint may be laterally offset from retainer702. For example, retainer 702 may be mounted along vertical plane 302,and the fastener joint may be spaced apart from vertical plane 302 alonglateral plane 304. In an embodiment, fastener 350 is laterally outwardfrom first end 322 of bottom strut 320. Thus, retainer 702 may limitmovement of PV frame 208 near vertical plane 302 where tool access maybe more difficult to achieve, and fastener 350 may be positioned at amore accessible location to resist shear loading.

Referring again to FIG. 9, retainer 702 is shown having a T-shapedconfiguration. That is, retainer tab 708 is a crossbar coupled toupright 706 near a medial location. Such configuration is offered by wayof example, however, and other retainer geometries having a vertical anda lateral component may be used. For example, the unitary structure ofretainer 702 may be split into two or more structures. Moreparticularly, one skilled in the art will understand that retainer 702may be separated along line of symmetry 908 to form two retainers 702out of what is shown as a left and a right side of a single retainer702. Each of the separate retainers 702 may then have respectiveL-shaped retainer geometries (inverted L shapes having horizontalportions extending away from line of symmetry 908). That is, eachretainer 702 could have retainer tab 708 extending from an end ofupright 706 in a respective direction opposite to the other retainer.

In an embodiment, upright 706 of retainer 702 may have a greater heightthan PV module 110. More particularly, whereas retainer 702 is describedabove as having retainer tab 708 to fit into slot 802, receiving gap 712may be as tall or taller than a vertical height of inward edge 306 of PVframe 208. Thus, retainer tab 708 may extend laterally from upright 706over a top surface of PV frame 208 and/or PV laminate 206.

In addition to retaining PV module 110, retainer 702 may also serve anelectrical grounding function. For example, retainer 702, PV frame 208,and one or more components of mounting assembly 202 may be formed froman electrically conductive metal, such as aluminum. Accordingly,retainer 702 may be fastened to, and press against, the conductivecomponent of mounting assembly 202 at base 704, and may engage theconductive PV frame 208 at lateral end 710 of retainer tab 708. In anembodiment, retainer 702 may include grounding features, such as teeth,roughened surface regions, pierce points, etc., to break throughanodization or oxidation of PV module 110. As such, an electricalgrounding path may be provided from PV frame 208 through retainer 702 tomounting assembly 202.

Assembly of the components described above may be performed in variousmanners. A method of assembling the components is described here,however, by way of example. At an installation site, pin 502 may beinserted through top support member hole 512 of top support member 314,and an upper mounting hole 410 of torque member 102. Pin 502 may extendfully through the inner lumen of torque member 102 to pass through alower mounting hole 410 of torque member 102. An upper end collar 518preloaded on pin 502 may rest on top mounting wall 504 and extendthrough member wall 402. Bottom support member 316 may be placed overpin 502 and against a lower outer surface 408 of member wall 402 suchthat pin 502 extends through bottom support member hole 514 of bottomsupport member 316. A lower collar end 518 may be placed over pin 502and inserted through bottom support member hole 514 and the lowermounting hole 410 of member wall 402. Nut 516 may be threaded onto pin502 and tighten down such that collar flange 524 clamps the supportmembers 314, 316 against member wall 402. Top strut(s) 319 and bottomstruts 320 may be fastened to respective bracket walls 602, andrespective first ends 322 of bottom struts 320 may be fastened to topstrut 319 to complete mounting assembly 202 mounted on torque tube. PVmodule 110 may be mounted on the assembled mounting assembly 202. Forexample, PV frame 208 may be placed on top strut 319 and slid towardretainer 702 until retaining tab 708 and/or upright 706 engage inwardend 306 of PV frame 208. PV frame 208 may be fastened to top strut 319at a laterally offset location from vertical plane 302, e.g., byfastener 350, to complete the PV module assembly 200.

Mounting assemblies for a PV module, and systems including such mountingassemblies, have been described. Although specific embodiments have beendescribed above, these embodiments are not intended to limit the scopeof the present disclosure, even where only a single embodiment isdescribed with respect to a particular feature. Examples of featuresprovided in the disclosure are intended to be illustrative rather thanrestrictive unless stated otherwise. The above description is intendedto cover such alternatives, modifications, and equivalents as would beapparent to a person skilled in the art having the benefit of thisdisclosure.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims may be formulatedduring prosecution of this application (or an application claimingpriority thereto) to any such combination of features. In particular,with reference to the appended claims, features from dependent claimsmay be combined with those of the independent claims and features fromrespective independent claims may be combined in any appropriate mannerand not merely in the specific combinations enumerated in the appendedclaims.

What is claimed is:
 1. A photovoltaic (PV) module assembly, comprising:a torque member extending along a longitudinal axis and pivotable aboutthe longitudinal axis, wherein the torque member includes a convexmember wall having a. top mounting hole; a mounting assembly comprising:a top support member including a top mounting wall having a concavedownward surface facing the torque member, and a top support member holeextending through the top mounting wall, wherein the top support memberhole is centered within the concave downward surface of the top mountingwall of the top support member, and a pin assembly including a pinextending along a pin axis through the top mounting hole and the topsupport member hole; and a PV module mounted on the top support member.2. The PV module assembly of claim 1, wherein the mounting assemblyfurther comprises: a bottom support member including a bottom mountingwall and a bottom support member hole extending through the bottommounting wall.
 3. The PV module assembly of claim 2, wherein the bottommounting wall includes a concave upward surface facing the torquemember.
 4. The PV module assembly of claim 2, wherein the bottom supportmember hole is centered the bottom mounting wall of the bottom supportmember.
 5. The PV module assembly of claim 1, wherein the top supportmember includes one or more top struts extending orthogonal to the pinaxis and outward from the top mounting wall, wherein the PV module ismounted on the one or more top struts.
 6. The PV module assembly ofclaim 1, wherein the pin assembly includes an end collar disposed in thetop support member hole, and wherein the end collar includes a collardiameter greater than a pin diameter of the pin.
 7. The PV moduleassembly of claim 6, wherein the collar diameter is at least twice thepin diameter.
 8. The PV module assembly of claim 7, wherein the endcollar includes a collar flange having a flange diameter greater thanthe collar diameter, and wherein the pin collar extends from the collarflange outside of the top support member to a collar end between the topsupport member through the top mounting wall.
 9. The PV module assemblyof claim 8, wherein the collar includes a collar height between thecollar flange and the collar end, and wherein the collar height is atleast twice a thickness of the top mounting wall.
 10. A photovoltaic(PV) module assembly, comprising: a PV system mounting structureincluding a member wall having an upward facing surface with a topmounting hole; a top support member including a top mounting wall havinga downward facing surface conforming to the member wall of the PV systemmounting structure; wherein the top support member further includes atop support member hole extending through the top mounting wall; the topsupport member hole being centered within the downward facing surface ofthe top support member, and a pin assembly including a pin extendingalong a pin axis through the top mounting hole and the top supportmember hole; and, a PV module coupled to the top support member.
 11. ThePV module assembly of claim 10, wherein the downward facing surface ofthe top mounting wall includes a concave downward surface facing the PVsystem mounting structure.
 12. The PV module assembly of claim 10further comprising: one or more top struts extending orthogonal to thepin axis and outward from the top mounting wall.
 13. The mountingassembly of claim 10, wherein the pin assembly includes an end collar,the end collar disposed in the top support member hole, and wherein theend collar includes a collar diameter greater than a pin diameter of thepin.
 14. The mounting assembly of claim 13, wherein the collar diameteris at least twice the pin diameter.
 15. The mounting assembly of claim13, wherein the end collar includes a collar flange having a flangediameter greater than the collar diameter.
 16. The mounting assembly ofclaim 15, wherein the end collar includes a collar height at least twicea thickness of the top mounting wall.
 17. A method of assembling aphotovoltaic (PV) module assembly, comprising: providing a PV systemmounting structure including a member wall having an upward facingsurface with a top mounting hole; positioning a top support memberhaving a top support member hole above the PV system mounting structure;the top support member including a top mounting wall having a downwardfacing surface conforming to the member wall of the PV system mountingstructure; aligning the top support member hole of the top supportmember with the top mounting hole of the PV system mounting structure;extending a pin along a pin axis through the top mounting hole and thetop support member hole; and, mounting a PV module to the top supportmember.
 18. The method of claim 17 further comprising: positioning abottom support member having a bottom support member hole below the PVsystem mounting structure; the bottom support member including a bottommounting wall having an upward facing surface conforming to the memberwall of the PV system mounting structure; aligning the bottom supportmember hole of the top support member with a bottom mounting hole of thePV system mounting structure.
 19. The method of claim 17, furthercomprising: mounting the PV module on one or more top struts of the topsupport member; wherein the one or more top struts extend orthogonal tothe pin axis and outward from the top mounting wall.
 20. The method ofclaim 17, further comprising: disposing an end collar of the pinassembly in the top support member hole.